Erosive Wear Behavior Research Articles

Comparative corrosion performance of YSZ-coated Ti-13Zr-13Nb alloy and commercially pure titanium in orthopedic implants

This study delves into the corrosion performance and wear behavior of orthopedic implant alloys, particularly the Ti-13Zr-13Nb alloy and commercially pure titanium (cp-Ti), both coated with Yttria-Stabilized Zirconia (YSZ) nanoceramic. The research utilizes the Taguchi design of experiments (DOE) approach and employs electrophoretic deposition (EPD) techniques to create thin, well-adhering YSZ layers on these alloys. Employing an orthogonal Taguchi L9 array, the study investigates how various EPD parameters, including electrical voltages, YSZ concentration, deposition duration, and grinding intensity, influence the deposition yield on both Ti alloys. To optimize the EPD parameters for these Ti alloys, the coated substrates underwent thickness and adhesion tests. The optimal conditions established are as follows: for commercially pure Ti, YSZ coating thickness and adhesion were achieved using 60 Vs, 7 min of deposition, 15 % concentration, and 400° of grinding. Meanwhile, for Ti-13Zr-13Nb, the ideal parameters were 60 Vs, 7 min of deposition, 20 % concentration, and 400° of grinding. Comprehensive characterization techniques were employed, including high-resolution scanning electron microscopy (FE-SEM) for alloy analysis, optical microscopy and atomic force microscopy (AFM) for surface microstructure and thickness evaluation, energy-dispersive X-ray spectroscopy (EDAX) for composition analysis, and X-ray diffraction (XRD) for phase analysis.The research goes on to assess corrosion resistance by subjecting the optimal coated Ti alloys to simulated body fluid (SBF) using electrochemical methods such as polarization (Tafel) and cyclic polarization. Additionally, adhesion force was measured using a tip tester. Notably, both cp-Ti and Ti-13Zr-13Nb coatings showcased enhanced corrosion resistance in Ringer's solution at 37 °C. Importantly, the corrosion rate of the coated Ti-13Zr-13Nb alloy (1.888 × 10–3) was found to be lower than that of the coated cp-Ti alloy (3.013 × 10–3)..

Erosion behaviour of Fe-Cr-C alloys: Cast alloy versus coating

Abstract: This research focuses on the erosion wear behaviour of two Fe-Cr-C alloys with similar chemical compositions obtained using different production methods. The first alloy belongs to the high chromium cast irons (HCCI). It was made by casting, after which the samples were heat treated by annealing. The second alloy in the form of the coating was applied by the plasma transferred arc (PTA) surface welding process at the substrate material (structural carbon steel). Damage to the components of industrial plants due to erosive and/or abrasive wear is a frequent cause of failure and outages of such systems. For this reason, and to bring the experimental research closer to real service conditions, an erosion test was performed at a gas blast sand facility with a high erodent speed of 90 m/s and a higher feed rate than standard erosion testing parameters recommended in ASTM G76 standard. Microstructural characterisation of all samples was done using a scanning electron microscope (SEM). The X-ray diffraction analysis (XRD) was used to identify the phases present. Similar erosion mechanisms were observed on all tested specimens, but coated samples (PTA alloy) had a lower mass loss during the erosion test compared to cast samples (HCCI alloy), i.e. they showed better erosion resistance.

Effect of impingement angle and impact velocity on slurry erosive wear behaviour of particulate reinforced aluminium composites

Effect of impingement angle and impact velocity on slurry erosive wear behaviour of particulate reinforced aluminium composites

Physical and mechanical characterization of glass fiber‐grewia optiva fiber reinforced hybrid polymer composite fabricated by vacuum assisted resin transfer moulding

AbstractThe natural and synthetic fibers are combined in a single composite to achieve a balance between the desired strength and cost considerations. In this study, the vacuum resin transfer moulding process was used to prepare an epoxy‐based composite. The composite consisted of grewia optiva as the natural fiber and glass fiber as the synthetic fiber, both with a fixed weightage of 10 %. Dolomite was used as a filler with varying content (0 %, 5 %, 10 %, and 15 weight %). The physical, mechanical, erosion wear and morphological behavior of the epoxy‐based composite were investigated. The inclusion of dolomite filler significantly increased the composite hardness and impact strength but reduced its tensile and flexural strength. At a dolomite filler content of 10 weight %, the erosive wear was reduced, while it increased at higher dolomite filler contents. The composite was examined using the L16 array, and the minimum wear rate was observed at an impingement angle of 30°, a velocity of 10 m/s, and an erodent size of 150 μm. Morphological studies were conducted to explore the possible mechanism for the variation in erosive wear at different dolomite contents in the hybrid composites.

Erosive Wear Behavior of Forged AA7075 under Different Temper Conditions

Erosive Wear Behavior of Forged AA7075 under Different Temper Conditions

Effect of Impact Velocity and Impingement Angle on the Erosive Wear Behavior of Ceramic Reinforced Polymer Composites

Effect of Impact Velocity and Impingement Angle on the Erosive Wear Behavior of Ceramic Reinforced Polymer Composites

Application of Discrete Element Method Coupled with Computational Fluid Dynamics to Predict the Erosive Wear Behavior of Arctic Vessel Hulls Subjected to Ice Impacts

Marine vessels operating on the Arctic Sea route are constantly prone to collisions and friction with ice. This study discusses the wear of the hull plate caused by the collision of ice against vessels operating in Arctic Sea routes. The abrasive wear of the hull due to ice impact was numerically assessed based on both the incident behavior of ice particles interacting with the flow around the hull and the wear loss of the hull surface caused by the contact force of ice particles. A multi-phase approach was adopted to account for the behavior of ice particles continuously affected by the fluid force around the hull. The fluid force acting on the ice floe was evaluated using computational fluid dynamics (CFD) and the dynamic motion of the drift ice was evaluated using the discrete element method (DEM). The motion of the floating ice particles was updated in real time by iteratively coupling the fluid force and the motion of the ice floe at each time step of the numerical simulation. The results of the wear simulation models were presented in terms of the shape change of the hull surface due to wear. At first, the wear was evaluated for cases in which only the surface paint of the hull was damaged. Thereafter, a computation model considering the shape change of the hull surface experiencing long-term friction of ice particles was introduced. Finally, the numerical procedures to predict the abrasive wear of the hull surface by ice impact were discussed.

Effect of Cr addition on the Corrosion-Wear Behaviors of 18Mn(V, Mo) Steel in a Seawater Environment

The objective of this study was to examine the wear-corrosion behavior of 18Mn(V, Mo) steel, which had a minor amount of Cr addition (< 3 wt%), in an artificial seawater environment, and compare it to conventional carbon steel. A variety of electrochemical experiments, including linear polarization resistance, impedance spectroscopy, and galvanostatic polarization, were conducted, along with weight loss measurements after immersion and wear-corrosion testing. These tests aimed to determine the static corrosion and wear-corrosion mechanisms of 18Mn(V, Mo) steel with respect to Cr addition. The results of this study indicated that the addition of Cr to 18Mn(V, Mo) steel refined the V4C3 particles in the microstructure, which led to an increase in surface hardness. Moreover, the 18Mn(V, Mo) steel with Cr addition exhibited the lowest corrosion and corrosion-wear losses, compared to 18Mn(V, Mo) steel without Cr and conventional carbon steel. This beneficial effect was primarily attributed to the formation of a thin Crenriched corrosion scale that adhered to the underlying steel. This corrosion scale served as a protective barrier against the penetration of corrosive species and as a lubricant for mechanical wear. The 18Mn(V, Mo) steel with Cr addition has potential application in various industrial fields, particularly in marine and offshore environments, owing to its low corrosion-induced wear loss rate in a brine environment.

The Effect of Processing Techniques and Operating Parameters on the Erosion Wear Behavior of Particle-Reinforced Metal Matrix and Surface Composites: A Review

The Effect of Processing Techniques and Operating Parameters on the Erosion Wear Behavior of Particle-Reinforced Metal Matrix and Surface Composites: A Review

Solid Particle Erosion and Scratch Wear Behavior of NiTi Smart Alloy Modified Mild Steel Using Atmospheric Plasma Spray Technology at Different Substrate Preheating Temperatures

Solid Particle Erosion and Scratch Wear Behavior of NiTi Smart Alloy Modified Mild Steel Using Atmospheric Plasma Spray Technology at Different Substrate Preheating Temperatures

Corrosion and Erosion Wear Behaviors of HVOF-Sprayed Fe-Based Amorphous Coatings on Dissolvable Mg-RE Alloy Substrates.

To suppress the corrosion and erosion wear of dissolvable magnesium alloy ball seats in wellbores, Fe-based amorphous coatings were deposited on dissolvable Mg-RE alloy substrates, and their microstructure, corrosion behavior, and erosion wear behavior were studied. The thickness of Fe-based amorphous coatings on dissolvable Mg-RE alloy substrates can reach 1000 μm without any cracks, and their porosity and amorphous contents are 0.79% and 86.8%, respectively. Although chloride ions will damage the compactness and protective efficacy of passive films, Fe-based amorphous coatings still maintain low corrosion current density (3.31 μA/cm2) and high pitting potential (1 VSCE) in 20 wt% KCl solution. Due to their higher hardness, the erosion wear resistance of Fe-based amorphous coatings is about 4.16 times higher than that of dissolvable Mg-RE alloy substrates when the impact angle is 30°. Moreover, the erosion rates of Fe-based amorphous coatings exhibit a nonlinear relationship with the impact angle, and the erosion rate reaches the highest value when the impact angle is 60°. The erosion wear mechanisms of Fe-based AMCs vary with the impact angles, including cutting, delamination, splat fracture, and deformation wear. This work can provide effective guidance for the corrosion and wear protection of plugging tools made from dissolvable magnesium alloy.

Elevated temperatures erosion wear behavior of HVOF sprayed WC-Co-Cr/Mo coatings on Ti6Al4V substrate

The present research aims to investigate the effect of different impact angles and temperatures on volumetric erosion loss of WC-Co-Cr coating containing 10 wt% Mo. The composite coating was developed using High-Velocity Oxy Fuel (HVOF) process on a titanium substrate (Ti-31). A solid particle erosion behavior of the coatings is carried out at different impact angles (30°, 60°, and 90°) and temperatures (200 °C, 400 °C,600 °C, and 800 °C). The volumetric erosion loss of the coated samples was measured using an air jet erosion tester at high temperatures using Al2O3 as an erodent. The XRD, SEM/EDS, porosity, density, microhardness, bond strength, and scratch tests characterized the as-sprayed coatings. The 3D optical profilometer was employed to evaluate the volumetric erosion loss and the mode of erosion. The scratch resistance of WC-Co-Cr coating is better than WC-Co-Cr/Mo coating. The WC-Co-Cr coating shows a brittle mode of erosion up to 600 °C and a ductile mode of erosion at 800 °C. In contrast, the WC-Co-Cr/Mo coating shows a brittle mode of erosion at 200 °C and a mixed mode of erosion at 400 °C to 800 °C. The volumetric erosion loss of WC-Co-Cr is less than WC-Co-Cr/Mo for all temperatures and impact angles. The formation of oxide phases on the coating surfaces demonstrates erosion resistance at high temperatures. The results of volumetric erosion loss measured by the weight loss method correlate well with a non-contact type 3D optical profilometer.

Erosion wear response of ramie‐epoxy composites using artificial neural network integrated with Taguchi technique

AbstractThis paper aims on evaluating the erosion wear behavior of epoxy composites reinforced with ramie fibers. The possibility of reinforcing ramie fiber to improvise the wear resistance of epoxy is investigated in this study. Composites are fabricated by reinforcing multiple layers of woven ramie fiber mats into epoxy resin using conventional wet lay‐up technique and erosion wear trials are conducted using solid particle erosion test setup. Taguchi analysis is done to assess the relative significance of each of the factors influencing the erosion rate using L16 orthogonal array. The analysis reveals that the impact velocity followed by impingement angle are the most significant control factors affecting the erosion wear rate of ramie‐epoxy composites. Steady state erosion analysis is done to ascertain the effect of each of the significant factors while keeping other factors fixed. Further, an analytical and predictive model based on the principle of neural computation is used to predict the rate of erosion wear of the composites and the obtained results are compared with the experimental outcomes. The worn morphologies of the eroded surfaces of the composites are studied and analyzed to identify possible mechanisms causing wear.

Corrosion wear behavior of 30CrNi2MoVA steel in simulated seawater

This study investigates the corrosion wear behavior of 30CrNi2MoVA steel in a simulated seawater environment using an electrochemical workstation and a friction-wear testing machine. The results indicate that under dry friction conditions, an increase in load leads to an increase in friction coefficient and wear depth. In seawater, an increase in speed results in a decrease in friction coefficient and an increase in wear depth, while the effect of load on material loss is minimal, highlighting the crucial role of speed in corrosion-wear behavior. The synergistic effect of corrosion and wear causes more severe damage than dry friction. The corrosion wear behavior of 30CrNi2MoVA steel is a dynamic process of “mechanical deoxidation-chemical reoxidation,” as evidenced by the change in corrosion potential from −0.6502 V to −0.8646 V and increased material loss.

Microstructure, mechanical properties and fretting corrosion wear behavior of biomedical ZK60 Mg alloy treated by laser shock peening

ZK60 magnesium alloy was treated with laser shock peening (LSP) technology at different laser energy densities. Fretting corrosion wear tests were conducted on the LSP-treated and untreated magnesium alloy samples in simulated body fluid condition. The microstructure, residual stress, surface hardness, tensile strength, and corrosion resistance were also tested to analyze their relationships with fretting corrosion wear behavior. Results showed that a maximum of 73.4% reduction of the fretting corrosion wear volume can be obtained by LSP treatment. The fine grain strengthening and the strain hardening caused by dislocation and twinning, and the compressive residual stress improve the surface hardness, tensile strength, and corrosion resistance at the same time, thus reducing the fretting corrosion wear.

Erosive Wear Behavior of Novel Hybrid Multicomponent Cast Alloys with Different C and B Contents

Multicomponent and high-boron cast alloys have been recognized as materials with excellent wear resistance due to the formation of hard phases called carbides and borides. However, the wear performance of the combination of these two materials called hybrid multicomponent cast alloys (HMCAs) has not been comprehensively studied. Therefore, this study will evaluate the effect of C (0–0.9 wt.%) and B (1.5–3.5 wt.%) addition on the erosion wear behavior of an HMCA containing 2.5 wt.% Ti, 10 wt.% Cr, and 5 wt.% each of V, Mo, and W. Shot-blast erosion testing was used to evaluate the wear resistance of each alloy. The test was conducted for 3600 s using 2 kg of irregularly shaped steel sand as a scraper at impact angles of 30°, 60°, and 90°. The results showed that the highest wear rate in 0C and 0.45C with 1.5–3.5% B occurred at an impact angle of 60° due to gouging and indentation mechanisms occurring simultaneously. However, different results occurred in the case of 0.9C with the same amount of B where the wear rate increased with increasing impact angle due to brittleness. Based on the chemical composition, the wear resistance of the alloy increased with increasing C content due to higher hardness values. However, the reverse performance occurred when the addition of B exceeded the threshold (more than 1.5 wt.%) despite the higher hardness. This fact was due to the susceptibility to carbide cracking as the amount of B increased. Therefore, the alloy with the best erosion wear resistance was 0.9C–1.5B HMCA.

Investigation of tool wear rate during micro-electrochemical spark machining process

Micro-electrochemical spark machining (micro-ECSM) process exhibits good potential to process any materials with high dimensional accuracy and surface quality. However, the tool erosion (due to sparking) in different directions affects the accuracy of the finished features. Tungsten carbide (WC) material is widely used as a tool material to minimize dimensional inaccuracy of the machined part. Tungsten is a potential alternative tool material for this process, having melting point higher than WC. Due to the high melting point, the radial and axial erosion may be reduced significantly. The in-depth study on tungsten tool erosion (wear) behaviour has not been studied widely. In this work, the influence of different input machining parameters on tool erosion behaviour has been explored. The influence of voltage, duty factor, pulse frequency, electrolyte type, their concentrations, and tool immersion length in the electrolyte was considered for the analysis purpose. The results reveal that voltage is the most influencing parameter for tool erosion which mainly occurs at the bottom edge, whereas electrolyte level is the least influencing parameter. The tool weight loss is increased to 153% by changing voltage from 50 V to 60 V whereas axial length loss is 146 µm at 60 V is observed. Further, the micro hole is fabricated at machining parameter voltage: 50 V, duty factor: 40%, frequency: 6 kHz, NaOH electrolyte of concentration 2 M, and 2 mm electrolyte level. The wall surface of the hole shows an average surface roughness of 4.31 µm having the average recast layer thickness and HAZ of 31 µm and 56 µm, respectively, at the edge of the hole.

Microstructure and corrosion-wear behaviors for laser cladding repaired martensitic stainless steels using Co-based and Ni-based powders

Structural components always suffer severe surface damage (i.e., abrasion and erosion) during long-term service in harsh environments, and laser cladding is a highly efficient method for repairing components. In this work, the laser cladding technique was conducted on 1Cr12 martensitic stainless steel using Co-based and Ni-based alloys as feedstocks for improved wear/corrosion resistance, and the defect density, microstructural evolution, and corrosion-wear resistances of the repaired counterparts were systematically evaluated. Results show that the defect densities of CoCrMo+WC and NiCoCr repaired parts are comparatively high at 1.61 % and 0.98 %, respectively. In contrast, NiCrMoNb+WC and Stellite 6 repaired parts exhibit more favorable dilution rates, reaching 5.4 % and 3.1 %, respectively. The coatings evolve from columnar dendrites to equiaxed grains along the building direction. Moreover, the addition of WC particles significantly hinders the epitaxial growth of columnar dendrites, leading to local orientation variations and a transition from columnar to equiaxed crystals with refined grains. The corrosion resistance and tribological properties of the 1Cr12 matrix are significantly improved after reparation, and Stellite 6 repaired parts exhibit a high pitting potential of about 0.83 VSCE in a chloride-containing solution, together with a low wear rate of 1.4 × 10−5 mm3/N m. The underlying wear resistance mechanisms for different laser cladding candidates are elucidated and our work demonstrates that the Co-based and Ni-based alloys are excellent coating materials for repairing structural components.

Effect of Carbon and Titanium Addition on Erosive Wear Behavior of High Chromium White Cast Irons

Effect of Carbon and Titanium Addition on Erosive Wear Behavior of High Chromium White Cast Irons

Erosion wear analysis of coconut shell dust filled epoxy composites using computational fluid dynamics and Taguchi method

This article depicts the solid particle erosion wear behavior of the coconut shell dust-filled epoxy composites. The erosion wear behavior of the composites is evaluated by a solid erosion test rig according to Taguchi’s design-of-experiment approach. The experiments are carried out by both sand and Al2O3 erodent. The study shows that the inclusion of coconut shell dust improves the erosion behavior of epoxy resin. The wear behavior analysis also reveals that erodent size, angle of impingement (B), and impact velocity (C) are the most significant factors in that sequence that influence the erosion rate of the composites. Further, computational fluid dynamics analysis (CFD) is implemented to study the temperature and velocity gradient of the composites under an erosive environment. The experimental results are validated with CFD simulation results, and both values are found to be in better agreement.